Electric vehicle comprising a cover structure and battery storing case

Abstract: To improve a waterproof performance of a front surface of a battery storing case in an electric vehicle. A cover structure for an electric vehicle wherein subcovers 54a and 96a are provided between a front fender 80 covering a front wheel and a front surface of a battery storing case, and a gap generating between the subcovers 54a and 96a and the fender 80 or the front surface of the battery storing case is formed like a maze so as to stop an upward flow of muddy water.

Description: Field of the Invention The present invention relates to an electric vehicle comprising a battery storing case and a cover structure for said battery storing case. Prior Art The present applicant has already proposed a battery supporting device for an electric vehicle in Japanese patent laid-open No. 5-112270, in which there is shown a motorcycle having a plurality of batteries 15 arranged under a step floor 5. The batteries 15 are stored in a battery case 12. The battery case 12 is located just behind a front wheel, so that muddy water splashed by the front wheel directly strikes against the battery case 12. Accordingly, the battery case 12 is required to have a strict sealing structure. The document EP-A-0 469 995 discloses an electrically powered vehicle according to the preamble of claim 1, wherein a battery frame is arranged behind a front wheel of the vehicle and is surrounded by a cover. This cover extends along the rear side of the battery frame, along the whole length of the battery frame, and along the front side of the battery frame and upwards to a vehicle main frame portion located behind and above the front wheel. Further, the front wheel is covered substantially at the upper side thereof by a fender. Problem to be solved by the invention It is an object of the present invention to provide an electric vehicle comprising a relatively simple cover structure for a battery storing case, wherein the cover structure prevents water from entering the battery storing case. Means for solving the problem According to the present invention, there is provided an electric vehicle according to claim 1. Operation The subcover functions to receive water splashed by the wheel and the gap relating to the subcover forms a maze structure; thereby the water is prevented from entering the battery storing case and an upward flow of the water splashed by the wheel is stopped thereby. Effect of the invention As described above, according to the present invention, in a cover structure for an electric vehicle having a battery storing case provided behind a wheel, a subcover is provided between a fender covering the wheel and a front surface or front cover of the battery storing case, and a gap extends between the fender and the front surface or front cover of the battery storing case, which is formed like a maze so as to stop an upward flow of water. Accordingly, the entry of the water splashed by the wheel into the battery storing case can be effectively prevented. Advantageous developments of the inventive vehicle are given in the dependent claims. Especially there can be provided an electric vehicle as defined by claim 6. Accordingly, the muddy water flowing along the lower surface of the bottom plate is prevented from entering the battery storing case. Moreover, water present in the battery storing case can be discharged through the first passage portion and the second passage portion. Since the second passage portion opens to the rear side of the vehicle, there is no possibility that the water may reversely flow in the first and second passage portions to enter the battery storing case. In a form of the present invention, the bottom plate comprises a corrugated plate, and the second passage portion is formed between a crest and a trough of the corrugated plate. Accordingly, the second passage portion can be easily formed, so that a working cost for forming the second passage portion can be saved. Preferred embodiment A preferred embodiment of the present invention will now be described with reference to the accompanying drawings. Each drawing should be viewed in the same orientation as that of the reference numerals. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a side view of an electric vehicle according to the present invention; Fig. 2 is a plan view of the vehicle with a vehicular frame primarily illustrated according to the present invention; Fig. 3 is a transverse sectional view of the vehicle at a substantially central portion thereof according to the present invention; Fig. 4 is an exploded perspective view of the vehicular frame, a battery storing case, and accessories according to the present invention; Fig. 5 is an exploded perspective view of controllers, a rear fender, and parts provided near it according to the present invention; Fig. 6 is a side view of assembled fenders and covers of the electric vehicle according to the present invention; Fig. 7 is an exploded perspective view of the fenders and the covers at a front portion of the vehicle according to the present invention; Fig. 8 is an exploded perspective view of the fenders and the covers at a rear portion of the vehicle according to the present invention; Fig. 9 is an enlarged view of a rear portion of a seat of the vehicle according to the present invention (a view showing a combined seat lock mechanism and plug lid lock mechanism); Fig. 10 is a view taken in a direction shown by an arrow 10 in Fig. 9; Fig. 11 is a front view of a cover structure according to the present invention as viewed from the front side of the vehicle; Fig. 12 is a sectional side view of the cover structure shown in Fig. 11; Fig. 13 is a cross section taken along the line 13-13 in Fig. 11; Fig. 14 is a cross section taken along the line 14-14 in Fig. 12; and Fig. 15 is a longitudinal sectional view of a bottom plate of a battery storing case according to the present invention. Fig. 1 is a side view of an electric vehicle according to the present invention. The electric vehicle generally denoted by reference numeral 1 is a so-called electric motorcycle. A vehicular frame 2 of the electric vehicle 1 comprises a main frame 3, a head pipe 4 provided before the main frame 3, and a rear frame 5 provided behind the main frame 3. A front wheel 8 is mounted through a front fork 7 to the head pipe 4. A steering handle 9 is provided at an upper portion of the head pipe 4. A battery storing case 10 is suspended from the main frame 3. A power swing unit 14 (including a traveling motor 15) is pivotally connected at a front end thereof through right and left brackets 12 and a pivot shaft 13 to a rear portion of the main frame 3. A helmet storing portion 16 and a seat 17 are mounted on the upper side of the rear frame 5 inclined upwardly toward the rear end of the vehicle and a rear suspension 18 is mounted on the lower side of the rear frame 5. A rear portion of the power swing unit 14 is supported by a lower end of the rear suspension 18. A rear wheel 21 is mounted through an axle 19 to the rear portion of the power swing unit 14. Electric parts such as a charger are arranged along the rear frame 5, and the vehicular frame 2 is generally covered with a cowl and a fender. This construction will be hereinafter described in detail with reference to the different drawings. Further, while a combined seat lock mechanism and plug lid lock mechanism is provided behind the seat 17, this construction will also be hereinafter described in detail. In Fig. 1, 22 denotes a side stand; 23 denotes a roller; 14a denotes a recess for receiving the roller 23; and 24 denotes a license plate mounting plate. Fig. 2 is a plan view of the vehicle according to the present invention in which the vehicular frame is primarily shown. As shown in Fig. 2, the rear frame 5 is substantially O-shaped in plan. Inside the rear frame 5 there are arranged a down regulator 27, controllers 28 and 29 (the controller 28 is a charge controller for performing control in charging batteries and the controller 29 is a travel controller for performing control of a motor or the like in relation to traveling of the vehicle), a battery cooling fan 30, and a fuse box 31 in this order from the rear toward the front of the vehicle. 32 denotes a harness for connecting electric components. The main frame 3 is a hollow pipe, which also serves as an air duct connected at one end thereof to a discharge duct 33 of the battery cooling fan 30. The structure of the main frame 3 also serving as the air duct will be hereinafter described. In this preferred embodiment, six batteries 35 are mounted to the main frame 3 and are arranged in right and left, two rows each consisting of three batteries and extending in a longitudinal direction of the vehicle. 36 denotes a battery fixing band for each battery. Fig. 3 is a transverse sectional view of the vehicle at a substantially central portion thereof according to the present invention. As shown in Fig. 3 viewed from the front of the vehicle, it is featured that a bottom plate 38 of the battery storing case 10 is located under the main frame 3, that the batteries 35 are placed on the bottom plate 38, and that an air induction hole 35a of each battery 35 is in contact with the main frame 3 through a branch passage 40. The bottom plate 38 is a so-called corrugated plate, which is so formed as to have a large rigidity in a vertical direction. The battery fixing bands 36 are engaged at their lower ends with hinges 39 formed at right and left ends of the bottom plate 38. Fig. 4 is an exploded perspective view of the vehicular frame, the battery storing case, and accessories. Although not described with reference to Figs. 2 and 3, a bridge bracket 41, a cross pipe 43 having a mounting tab 42 for the rear suspension 18, and a cross panel 45 having cooling fan mounting holes 44 extend between right and left curved portions of the O-shaped rear frame 5 in the transverse direction of the vehicle. The cross panel 45 is a member also extending between the right and left brackets 12 for supporting the pivot shaft 13. 46 and 47 denote controller mounting tabs. Substantially triangular support brackets 49, 50, and 51 are suspended from the main frame 3 to support the bottom plate 38. The lower ends of the battery fixing bands 36 are fitted with the hinges 39 of the bottom plate 38 on each side, and are pivotally supported by an elongated pin 52. 54 denotes a battery case side lower cover for covering a lower portion of each side of the battery storing case 10; 55 denotes a battery case front cover for covering a front end of the battery storing case 10; 56 denotes a main switch with an ignition key switch; 57 denotes a battery receiving plate; and 58 and 59 denote cushion members (which prevent transverse slip of each battery 35). Fig. 5 is an exploded perspective view of the controllers, a rear fender, and parts provided near it. A controller front support 61 is bolted to the controller mounting tabs 46 shown in Fig. 4, and a controller rear support 62 is bolted to the controller mounting tabs 47 shown in Fig. 4. The controller front support 61 is provided with an upper mounting tab 63 for mounting the battery cooling fan 30, bolts 64 for supporting a front portion of the charge controller 28, and leg portions 61a and bolts 65 for supporting the travel controller 29. The controller rear support 62 is provided with bolts 66 for supporting a rear portion of the charge controller 28 and leg portions 62a and bolts 67 for supporting a rear portion of a rear fender 69. The rear fender 69 is located over the rear wheel 21 not shown in Fig. 5 to originally serve as a mudguard and also serve as a storing box for the controllers 28 and 29 etc. as shown. The charge controller 28 must be forcibly cooled because internal elements generate heat during charging. Accordingly, the charge controller 28 is provided with a charger cooling fan 71 and an air induction hole 72. 73 denotes a charging cord, and 74 denotes a charging plug. The charging cord 73 is stored in a charging cord box 76. The charging cord box 76 is formed as a resin blow molding, and it is fixed at mounting tabs 76a and 76b to the vehicular frame 2. 77 denotes an air discharge hose for permitting heat inside of the charger to escape. 78 denotes a tail fender, and 79 denotes a stay for mounting the tail fender 78. Fig. 6 is a side view of assembled fenders and covers of the electric vehicle according to the present invention; Fig. 7 is an exploded perspective view of the fenders and the covers at the front portion of the vehicle; and Fig. 8 is an exploded perspective view of the fenders and the covers at the rear portion of the vehicle. Referring to Fig. 7, 80 denotes a front fender; 81 denotes a front inner upper cover; 82 denotes a front cover mounted on a front upper portion of the front fender 80; 83 denotes a fender mudguard mounted on a front lower portion of the front fender 80; 84 denotes a steering mudguard; 85 denotes a front inner lower cover; 86 denotes a step floor; and 87 denote right and left side floors. These parts are so mounted as to cover the main frame 3 and the head pipe 4 as shown in Fig. 6. Referring to Fig. 8, 90 denotes a body main cover, and 91 denotes a center cover. These parts are so mounted as to cover the helmet storing portion 16. 92 denotes a fuse box lid, which is operated for replacement of a fuse at any time. 93 denotes a first lid for closing a cord outlet opening; 94 denotes a second lid for closing the cord outlet opening; 95 denotes a rack; 96 denote right and left floor side covers suspended from the step floor 86 to cover right and left side portions of the battery storing case 10; and 97 denotes right and left side covers extending along right and left lower edges of a rear portion of the body main frame 90. These parts are so mounted as to cover the main frame 3 and the rear frame 5 as shown in Fig. 6. Parts shown by broken lines in Fig. 6 are the same as those shown in Fig. 1; so the explanation thereof will be omitted herein. Fig. 9 is an enlarged view of a rear portion of the seat of the vehicle according to the present invention (a view showing a combined seat lock mechanism and plug lid lock mechanism). A bent bar (or bent pipe) 101 is mounted to a rear lower portion of the seat 17 closing an upper opening of the helmet storing portion 16. A seat switch 102 is located under the bent bar 101. The seat switch 102 is bolted through a switch mounting plate 103 to the bridge bracket 41. The switch mounting plate 103 will be hereinafter described in detail. The charging cord 73 shown in Fig. 1 can be drawn out by first opening the seat 17, secondly opening the first lid 93, and finally opening the second lid 94. 105 denotes a plug stop for retaining a plug provided at one end of the charging cord 73. 106 denotes a key cylinder, and 107 denotes a lever linked to the key cylinder 106. When the key cylinder 106 is turned, the lever 107 is raised to permit the seat 17 to be opened. This mechanism will be next described in detail. Fig. 10 is a view taken in a direction shown by an arrow 10 in Fig. 9. The switch mounting plate 103 is a plate member having a guide groove 108 for guiding the bent bar 101 at an upper portion and also having two arcuate holes 109 and 110 at right and left lower portions. The seat switch 102 is secured to a small bracket 112 by a bolt 111. The small bracket 112 is welded to a front surface of the switch mounting plate 103. Thus, the seat switch 102 is mounted to the switch mounting plate 103 at a central lower portion thereof. A first swing plate 114 for depressing the seat switch 102 by a lowering motion of the bent bar 101 is pivotably mounted to the switch mounting plate 103. Further, a second swing plate 116 is pivotably mounted to the switch mounting plate 103. The first switch plate 114 is normally biased in a counterclockwise direction by a spring 117, and the second swing plate 116 is normally biased in a clockwise direction by the spring 117. When a passenger leaves the seat 17, the first swing plate 114 is slightly rotated in the counterclockwise direction from the position shown in Fig. 10 by the operation of the spring 117, so that an arm 118 of the first swing plate 114 comes into abutment against a cam 119 of the second swing plate 116 to stop in this position. Since the second swing plate 116 is in rest, no further rotation of the first swing plate 114 in the counterclockwise direction is inhibited, so that further rising of the bent bar 101 is restricted by the first swing plate 114. Accordingly, the seat 17 is locked to keep closed. In other words, when a passenger sits on the seat 17, the first swing plate 114 is rotated in the clockwise direction by the bent bar 101 to depress the seat switch 102 and close it as shown in Fig. 10. Conversely, when the passenger leaves the seat 17, the first swing plate 114 is slightly rotated in the counterclockwise direction from the condition shown in Fig. 10 by the operation of the spring 117 to thereby open the seat switch 102. Thus, the presence or the absence of the passenger on the seat 17 can be electrically detected with the seat 17 kept locked. The seat 17 is opened in the following procedure. First, the key cylinder 106 shown in Fig. 9 is turned to raise the lever 107. As a result, the second swing plate 116 shown in Fig. 10 is rotated in the counterclockwise direction, and the cam 119 of the second swing plate 116 becomes lower in level than the arm 118 of the first swing plate 114. As a result, the locking operation of the cam 119 is lost, and the first swing plate 114 is largely rotated in the counterclockwise direction by the operation of the spring 117 to permit free rise of the bent bar 101. Thereafter, the seat 17 is opened by hand. Fig. 11 is a front view of a cover structure according to the present invention as viewed from the front side of the vehicle. The floor side covers 96 are mounted to right and left lower portions of the front fender 80, and the battery case side lower covers 54 are mounted inside and under the floor side covers 96. While the floor side covers 96 and the battery case side lower covers 54 are so mounted as to cover right and left sides of the battery storing case 10, front portions (which will be hereinafter referred to as "first subcovers") 96a of the floor side covers 96 are bent toward the transverse center of the vehicle and are secured to the front fender 80 by clips 151, and similarly front portions (which will be hereinafter referred to as "second subcovers") 54a of the battery case side lower covers 54 are bent to the transverse center of the vehicle and are secured to the battery case front cover 55 by a common clip 152. It is featured that the first subcovers 96a, the second subcovers 54a, and the battery case front cover 55 are mounted in this order from the front to the rear of the vehicle, and especially that the battery case front cover 55 is formed as a large, substantially rectangular plate to substantially close a large opening 80a of the front fender 80. Fig. 12 is a sectional side view of the cover structure shown in Fig. 11. The battery case front cover 55 behind the front fender 80 is mounted to the vehicular frame 2 by inserting a tongue portion 55a formed at an upper end of the cover 55 into a receiving portion 2a of the vehicular frame 2 and bringing a key hole 55b formed at a transverse central, lower portion of the cover 55 into engagement with a pin head 153 provided on the front surface of the support bracket 49. Fig. 13 is a cross section taken along the line 13-13 in Fig. 11. There is shown in Fig. 13 a mounting structure such that each second subcover 54a is disposed just before the lower end of the battery case front cover 55, each first subcover 96a is disposed closely before the second subcover 54a, and the first subcover 96a is closely mounted on the front fender 80 by the corresponding clip 151. Fig. 14 is a cross section taken along the line 14-14 in Fig. 12, illustrating a covered condition of the battery storing case 10. That is, the batteries 35 arranged in the right and left rows below the main frame 3 and placed on the bottom plate 38 are covered with the step floor 86 on the upper side, with the floor side covers 96 on the right and left upper sides, and with the battery case side lower covers 54 on the right and left lower sides. Fig. 15 is a longitudinal sectional view of the bottom plate 38 of the battery storing case 10 according to the present invention. The bottom plate 38 is formed as a saw-toothed corrugated plate in order to improve a flexural rigidity. A rear end 38a of the bottom plate 38 is in close contact with a square bar 154 extending between the right and left brackets 12 which support the pivot shaft 13. On the other hand, a front end 38b of the bottom plate 38 is welded to the support bracket 49 only at trough portions 38c of the bottom plate 38 with a given passage space 155 defined between the front end 38b and the support bracket 49. This passage space 155 is composed of first passage portions 156 having upper ends exposed into the battery storing case 10 and second passage portions 157 having front ends connected with lower ends of the first passage portions 156 and rear ends exposed to the outside of the battery storing case 10. The operation of the cover structure shown in Figs. 11 to 15 will now be described. Referring to Fig. 11, when the front wheel 8 is rotated at high speeds to splash muddy water on the road, it is anticipated that the muddy water strongly strikes against an area near the clips 152 and 151 behind the front wheel 8. In particular when the front wheel 8 rushes into a water pool, the water pool is cut in a V-shape by the front wheel 8. Accordingly, the muddy water more strongly strikes against the area near the clips 151. The second subcovers 54a are overlapped and secured together by the clip 152 at the transverse center of the vehicle, so that a high waterproof performance at this portion can be ensured. Further, as shown in Fig. 13, it is featured that each first subcover 96a is overlapped with the lower end of the front fender 80 near the corresponding clip 151; that the rear end of the first subcover 96a is in close contact with the corresponding second subcover 54a; and that an upper end 54b of each second subcover 54a is bent to the front side of the vehicle. Accordingly, a splash of muddy water from the road (as shown by an arrow 1) is basically stopped by each first subcover 96a. Further, the remainder of the muddy water forced upward between the first subcover 96a and the corresponding second subcover 54a is stopped by the upper end 54b of each second subcover 54a. Thus, the entry of the muddy water can be effectively prevented by such a maze structure. Referring next to Fig. 15, the splash of the muddy water also strikes against the lower surface of the bottom plate 38 as shown by an arrow 2. However, since the rear end 38a of the bottom plate 38 is in close contact with the square bar 154, the muddy water is prevented from entering the battery storing case 10 from this portion. Further, a small amount of water gathered inside the battery storing case 10 because of dewing of the inside air, for example, is discharged through the first passage portions 156 at the front end 38b of the bottom plate 38 and the second passage portions 157 defined by the crests and the troughs of the bottom plate 38 as shown by an arrow 3. Since the first passage portions 156 and the second passage portions 157 form a maze passage and the splash of the muddy water from the road comes in the direction shown by the arrow 2, there is no possibility that the muddy water may reversely flow in the maze passage to enter the battery storing case 10. Although the cover structure is applied to the front wheel 8 and the front fender 80 in the above preferred embodiment, it may be applied to the rear wheel 21 and the rear fender 69. In summary, there is provided an improvement in waterproof and drain performances of a cover and a battery storing case in an electric vehicle.

Claims: An electric vehicle, comprising a battery storing case (10) provided behind a wheel (8) of said electric vehicle, a fender (80) covering said wheel (8), and a cover structure for said battery storing case (10), comprising a front surface or a front cover (55) and forming a gap between said fender (80) and said front surface or front cover (55), characterized in that said cover structure comprises a subcover (96a, 54a) extending into the gap, said fender (80), said subcover (96a, 54a) and said front surface or front cover (55) forming a maze structure for stopping an upward flow of water splashed by the wheel (8). An electric vehicle according to claim 1, wherein an upper end (54b) of the subcover (96a, 54a) disposed in said gap is bent towards the front side of the vehicle. An electric vehicle according to claim 1 or 2, wherein said subcover (96a, 54a) is formed by front portions of battery side covers (96, 54), which are bent towards the transverse center of the vehicle and are secured together. An electric vehicle according to claim 1, 2 or 3, wherein said subcover (96a, 54a) comprises a first subcover (96a) and a second subcover (54a), said first subcover (96a) being closely mounted on the front fender (80) and disposed closely before the second subcover (54a), said second subcover (54a) being disposed just before the lower end of the battery case front surface or front cover (55) and having an upper end (54b) extending into the gap. An electric vehicle according to claim 4, wherein said first subcover (96a) is overlapped with the lower end of the fender (80). An electric vehicle according to any of claims 1 - 5, wherein said battery storing case (10) comprises a bottom plate (38) on which a battery (35) is placed, right and left ends of said bottom plate (38) are in close contact with battery case side covers (54), a rear end (38a) of said bottom plate (38) is in close contact with a vehicular frame (2), and a front end (38b) of said bottom plate (38) is separate from said vehicular frame (2) to define a passage space therebetween, said passage space comprising a first passage portion (156) having one end exposed into said battery storing case (10) and a second passage portion (157) having one end connected to another end of said first passage portion (156) and another end opened to an outside of said battery storing case (10), said second end of said second passage portion (157) being directed in rearward direction. An electric vehicle according to claim 6, wherein said bottom plate comprises a corrugated plate (38), and a portion (157) of said passage (156, 157) is formed between a crest and a trough of said corrugated plate (38).

Inventors: OGAWA MASAO, SAKO HIROYUKI, SHIMMURA HIROYUKI, OGAWA, MASAO, SAKO, HIROYUKI, SHIMMURA, HIROYUKI, OGAWA, MASAO, C/O KABUSHIKI KAISHA HONDA, SAKO, HIROYUKI, C/O KABUSHIKI KAISHA HONDA, SHIMMURA, HIROYUKI, C/O KABUSHIKI KAISHA HONDA
Applicants: HONDA MOTOR CO LTD, HONDA GIKEN KOGYO KABUSHIKI KAISHA
Application year: 1994
Main classification: B60K1
IPC codes: H01M2, B62M7, B60K1, B62J23, B62M23, B62K19, B62J9